Key blank and carrier adapted for positioning a key blank in a cutter during bit cutting

ABSTRACT

Implementations of key blank carriers or key blanks with a standard reference features may include alignment features on a key blank head, key blank tip, a key blank carrier coupled to a key blank sleeve and/or a key blank sleeve, and any feature directly attached to any portion of the key that may be used for referencing in the key duplication system, or any combination of these. The standard reference features may allow any key blank brand model to interface with the machine so as to consistently align each key, regardless of its make and model, for cutting in a universally configured key blank clamp that is clamped to reduce the movement of the key blank during duplication cutting.

CROSS REFERENCE TO RELATED APPLICATIONS

This document is a divisional application o U.S. patent application Ser.No. 13/728,890 to Mueller et al. entitled “Key Blank and Carrier Adaptedfor Positioning a Key Blank in a Cutter During Bit Cutting,”pending,which was filed Dec. 27, 2012 and is a Continuation-in-Part of U.S.patent application Ser. No. 13/183,982 to Mueller, et al. entitled “KeyBlank and Carrier Adapted for Positioning a Key Blank in a Cutter DuringBit Cutting,” now U.S. Pat. No. 9,073,133, which was filed on Jul. 15,2011 and claims the benefit of the filing dates of U.S. ProvisionalPatent Applications: 61/364,644 to Hagen et al. entitled “KeyDuplication Packaging and Standard Reference Features,” which was filedon Jul. 15, 2010; 61/413,099 to Hagen et al. entitled “Key DuplicationMachine Cutting System,” which was filed on Nov. 12, 2010; and61/497,468 to Hagen et al, entitled “Key Packaging and DuplicationSystems,” which was filed on Jun. 15, 2011; the disclosures of each ofwhich are hereby incorporated herein by reference.

BACKGROUND

1. Technical Field

Aspects of this document relate generally to key duplication. Morespecific implementations involve individual carriers for key blankswhich may be used as display and/or product dispensing packaging thataligns and positions a key blank in a key blank cutter without the needfor a separate clamp for each key type and model.

2. Background Art

Conventionally, when a master key for opening a lock is duplicated, itis conventionally duplicated by first classifying the master key to beable to identify an appropriate key blank into which to cut a bitpattern for the duplicate key, selecting the appropriate key blank tomatch the master key, placing the selected key blank in a key cutter,and cutting the bit pattern from the master key into a blade of the keyblank. Conventional systems have required the operation skills of atrained worker to properly select the appropriate key blank. An exampleof an elaborate system used to assist a trained worker in selecting anappropriate key blank and appropriately positioning and clamping theappropriate key blank and master key for cutting is disclosed in U.S.Pat. No. 5,443,339 to Heredia et al., titled “Method and Apparatus forAligning and Cutting Single-sided and Double Sided Keys.” In Heredia, aplurality of cassettes, each comprising its own clamp and cutterfixturing is provided. The trained worker selects an appropriate keyblank, an appropriate cassette for the particular key blank and clampsthe key blank into the cassette. Then the trained worker couples thecassette with a cutting wheel for cutting. More recent master keyidentification systems, such as that disclosed in U.S. Pat. No.6,836,553 to Campbell et al., titled “Key Identification System,” thedisclosure of which is hereby incorporated herein by reference,automatically identifies the appropriate key blank and indicates thatnumber for key selection.

A recent key duplication system described in International ApplicationNumber PCT/US2007/024522 to Freeman, et al. titled “Fully Automatic KeyDuplicating Machine with Automatic Key Model Identification System”sought to reduce the need for the operation skills of a trained workerby automatically identifying master keys and automatically cutting anddispensing a duplicate key from a limited selection of keys within thekey duplication system. Another recent key duplication system describedin U.S. Pat. No. 7,890,878 to Bass et al., titled “Object IdentificationSystem,” discloses a system that identifies an appropriate key blank byflashing a light adjacent the appropriate key blank on a product displaynext to a key blank cutter so that the user or a trained worker canselect the appropriate key for insertion into the key blank cutter.Other systems require changing of clamps for different key blank modelsto enable secure positional clamping of the different key blank modelsin relation to the cutting wheel of a key blank cutter.

Each key blank type and model is a little bit, and sometimes a lot,different from the others in its relative dimensions and keywaydimensions and placements. As a result, efforts to eliminate thenecessity for the operation skills of a trained worker has yieldeddifficulties in enabling a system to cut the wide variety of master keytypes and models accurately with little or no skill have yielded arelatively high rate of miscue keys from reasons such as an incorrectkey blank being selected, a key blank being inserted backwards or notfar enough, and from a key blank being moved during cutting due to notbeing clamped securely. Each of these issues may result in a duplicatekey being cut that does not match the master key and will not work inthe lock. Many times, however, the user who cuts a key or even thetrained worker who cuts a key is not aware that the duplicate key has anerror until the user tries the key in the lock at home and is frustratedthat another trip to the store is required to replace the miscut key.

SUMMARY

A key blank cutting carrier adapted for mechanical interface with a keyblank cutter may comprise a key blank carrier, a key blank recess withinthe carrier, the recess comprising at least two walls and sized andshaped to securely receive at least a portion of a key blank within therecess, and at least one key blank cutter alignment feature extendingfrom a surface of the carrier at an angle of at least 20 degreesrelative to the surface, the at least one key blank cutter alignmentfeature positioned on the carrier to mechanically engage a portion of akey blank cutter into which a portion of the key blank carrier is placedand align the key blank with the key blank cutter.

Particular embodiments may comprise one or more of the followingfeatures. The key blank cutter alignment feature may extend lengthwisealong at least a portion of a first wall of the at least two walls ofthe key blank recess. The at least one key blank cutter alignmentfeature may comprise a first side extending from the carrier at theangle of at least 20 degrees converging toward a second side extendingfrom the carrier at an angle of about 90 degrees. The key blank cutteralignment feature may be integrally forced with the key blank carrier.The key blank carrier may have an opening along a first edge thereof.The opening may comprise a beveled edge extending for at least a portionof the opening. The opening may be V-shaped. The carrier may comprise anelongated sleeve defining at least a portion of the key blank recess,wherein the sleeve further comprises a tip end and a head end, the headend comprising a substantially planar surface, the tip end being atleast partly formed by the at least two walls and at least twoadditional walls, wherein the tip end at least two walls and at leasttwo additional walls defining key blade carrier front and back sides andkey blade carrier hit and spine sides respectively, the key bladecarrier front side comprising at least one aperture extending throughthe key blade carrier front side along an edge of the front sidebordering the key blade carrier spine side. The at least one apertureextending through the key blade carrier front side may comprise at leasttwo apertures extending through the key blade carrier front side alongthe edge of the front side bordering the key blade carrier spine side.The carrier may comprise an elongated sleeve defining at least a portionof the key blank recess, wherein the sleeve further comprises a tip endand a head end, the head end comprising a substantially planar surface,the tip end being at least partly formed by the at least two walls andat least two additional walls, wherein the tip end at least two wallsand at least two additional walls defining key blade carrier front andback sides and key blade carrier bit and spine sides respectively, thekey blade carrier front side comprising at least one aperture extendingthrough the key blade carrier front side along an edge of the front sideon the key blade carrier bit side. The key blank carrier may comprise akey blank positioned within the recess in direct contact with the atleast two walls. The carrier may comprise an elongated sleeve definingat least a portion of the key blank recess, wherein the sleeve furthercomprises a tip end and a head end, the head end comprising asubstantially planar surface, the tip end being at least partly formedby the at least two walls and at least two additional walls, wherein thetip end at least two walls and at least two additional walls definingkey blade carrier front and back sides and key blade carrier bit andspine sides respectively, the key blade carrier front side comprising atleast one aperture extending through the key blade carrier front sidealong an edge of the front side on the key blade carrier bit side, thekey blade carrier bit side further comprises a shoulder band adjacent tothe head end between the head end and the at least one aperture, theshoulder band extending from the front side of the key blade carrier tothe back side of the key blade carrier.

A key blank cutting carrier adapted for mechanical interface with a keyblank cutter may comprise a key blank carrier body, a key blank recesswithin the key blank carrier body, the recess defined by at least twowalls and sized and shaped to securely receive at least a portion of akey blank within the recess, at least one key blank cutter alignmentfeature coupled to the carrier body and positioned on the carrier bodyto mechanically engage a portion of a key blank cutter into which aportion of the key blank carrier is placed, and a key blank burr removalopening in a first edge of the carrier body.

Particular embodiments may comprise one or more of the followingfeatures. The key blank burr removal opening may comprise a bevelededge. The key blank burr removal opening may comprise a V-shapedopening. The key blank carrier body may further comprise a substantiallyplanar surface, and the first edge of the carrier body forming a firstedge of the substantially planar surface. The carrier may comprise anelongated sleeve defining at least a portion of the key blank recess,wherein the sleeve further comprises a tip end and a head end, the headend comprising a substantially planar surface, the tip end being atleast partly formed by the at least two walls and at least twoadditional walls, wherein the tip end at least two walls and at leasttwo additional walls defining key blade carrier front and back sides andkey blade carrier bit and spine sides respectively, the key bladecarrier front side comprising at least one aperture extending throughthe key blade carrier front side along an edge of the front sidebordering the key blade carrier spine side. The at least one aperturemay extend through the key blade carrier front side comprises at leasttwo apertures extending through the key blade carrier front side alongthe edge of the front side bordering the key blade carrier spine side.The carrier may comprise an elongated sleeve defining at least a portionof the key blank recess, wherein the sleeve further comprises a tip endand a head end, the head end comprising a substantially planar surface,the tip end being at least partly formed by the at least two walls andat least two additional walls, wherein the tip end at least two wallsand at least two additional walls defining key blade carrier front andback sides and key blade carrier bit and spine sides respectively, thekey blade carrier front side comprising at least one aperture extendingthrough the key blade carrier front side along an edge of the front sideon the key blade carrier bit side, the key blade carrier bit sidefurther comprises a shoulder band adjacent to the head end between thehead end and the at least one aperture, the shoulder band extending fromthe front side of the key blade carrier to the back side of the keyblade carrier. The key blank carrier may comprise a key blank positionedwithin the recess in direct contact with the at least two walls.

A method of cutting a key blank to form a duplicate key may compriseinserting a key blank positioned in a key blank carrier into an openingin a key blank cutter, cutting a key bit pattern of a master key intothe key blank with a key blank cutting wheel, removing the cut key blankand key blank carrier from the key blank cutter, separating the cut keyblank from the key blank carrier, and moving a blade of the cut keyblank along a key blank burr removal opening on the key blank carrieruntil at least one burr is removed from the blade of the cut key blank.

The foregoing and other aspects, features, and advantages will beapparent to those artisans of ordinary skill in the art from theDESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

Particular illustrative implementations will hereinafter be described inconjunction with the appended drawings, where like designations denotelike elements, and:

FIG. 1 is a block diagram of a specific key duplication processembodiment;

FIGS. 2A and 2B are a front views of key blank carriers illustrating afirst set of features;

FIG. 3A is a side view of a key blank carrier with a retaining clip in aflexed position;

FIG. 3B is a side view of a key blank carrier with a retaining clip in arest position;

FIG. 3C is a tip end view of the retaining clip of FIG. 3A;

FIG. 3D is a back side view of the retaining clip of FIG. 3D;

FIG. 4 is a block diagram of a specific key cutting process embodiment;

FIGS. 5A-5E are cut away views of a key blank cutter during a key blankcutting process;

FIG. 6 is a front view of a key blank carrier illustrating additionalfeatures;

FIGS. 7A and 7B are front and back side views of key blank carriers fortwo different key models illustrating a key blank security feature;

FIGS. 8A and 8B are front and back side views of a key blank carrierillustrating a portion of the key blade sleeve removed in combinationwith a key blank security feature;

FIGS. 9A and 9B are front and back side views of key blank carriers fortwo different key models illustrating a portion of the key blade sleeveremoved in combination with a key blank security feature and a key blankhead channel;

FIG. 9C are distal tip end views of the key blank carriers of FIG. 9A;

FIG. 9D is a representation of a shape formed by the end view of thedistal end tip view footprint caused by from the sleeve tip andalignment ridges;

FIGS. 10A and 10B are distal tip end views of two different keycarriers;

FIGS. 11A and 11B are front and back side views of key blank carriersfor two different key models illustrating a different sized flag incombination with a key blank security feature;

FIG. 12 is a front perspective view of a key blank carrier comprising ahinged front side;

FIG. 13 is a front perspective view of a key blank carrier without afront side;

FIG. 14 is a front view of a side-mount key blank carrier;

FIGS. 15A-15G are views of a key blank with an oversized head and a keyblank carrier with a step between the substantially planar flag and thekey blank recess;

FIGS. 16A-16C are front, side and perspective views of a key blankcarrier comprising a key blank recess configured to receive a key blankhead;

FIGS. 17A-17C are front, side and perspective views of a key blankcarrier like that of FIGS. 16A-16C but comprising additional alignmentfeatures;

FIGS. 18A-18C are front, side and perspective views of a key blank withan alignment feature on the key tip; and

FIG. 19A-19C are front, side and perspective views of a key blank withan alignment feature on the key head.

FIG. 20 is a front perspective view of a key blank carrier with a keyblank burr removal opening.

FIG. 21 is a tip end view of the key blank carrier of FIG. 20.

FIG. 22 is a back side view of the key blank carrier of FIG. 20.

FIG. 23 illustrates tip end views of different individual key blankcarriers in a system of key blank carriers with a uniform sleevethickness.

DESCRIPTION

This disclosure, its aspects and implementations, are not limited to thespecific components, use or assembly procedures disclosed herein. Manyadditional components and assembly procedures known in the artconsistent with the intended key blanks, key blank carriers and/orassembly or cutting procedures for a key blank will become apparent foruse with implementations of key blanks and carriers from thisdisclosure. Accordingly, for example, although particular key blanksand/or carriers are disclosed, such key blanks, carriers andimplementing components may comprise any shape, size, style, type,model, version, measurement, concentration, material, quantity, and/orthe like as is known in the art for such key blanks, carriers andimplementing components, consistent with the intended operation and useof a key blank or carrier.

Implementations of key blank carriers or key blanks with a standardreference features may include alignment features on a key blank head,key blank tip, a key blank carrier coupled to a key blank sleeve and/ora key blank sleeve, and any feature directly attached to any portion ofthe key that may be used for referencing in the key duplication system,or any combination of these. Alignment of a key blank, and the alignmentfeatures on a key blank carrier or key blank, comprises alignment in thespatial x-y-z sense and may also comprise orientational or rotationalalignment. The standard reference features on a key blank carrier or mayallow any key blank brand model to interface with the machine so as toconsistently align each key, regardless of its make and model, in aproper position in relation to a key blank cutter and in a properorientation for cutting in a universally configured key blank clamp thatis adapted to the standard reference features and clamped to reduce themovement of the key blank during duplication cutting.

An overview for a process of enabling a user to cut its own duplicatekey is illustrated in FIG. 1. In particular embodiments, the key blankmay be vended from an associated key blank vending machine incommunication with the master key identifier. In other particularembodiments, other additional methods and/or system components may beused as well. The specific identification process used to identify themaster key make, model and bit pattern for selection of an appropriatekey blank is not crucial to the present disclosure and any method may beused in combination with the present disclosure. The specific cuttingand checkout processes are also not crucial to the present disclosureand any discussion of them is provided as an example for clarity ofdiscussion and is not intended as a limitation for use of the key blankcarriers discussed herein.

The present disclosure relates to a carrier associated with the keyblank and may be used for displaying or dispensing the key blank inaddition to its use as a fixture for holding the key during the cuttingprocess and even as the key blank packaging at checkout. Whether calleda carrier or packaging, its use with standard external features enablesa key blank cutter to have a standard key blank receiving aperture andstandard key blank carrier clamping components despite the largevariations between various key blanks, enabling the key blank cutter tohave a standardized key blank clamp to cut all side-cut key blanks usingthe same key blank clamp rather than the conventional systems whichrequired a plurality of separate clamp units.

FIGS. 2A and 2B illustrate a particular implementation of a key blankcarrier 2, 4, adapted to two very different key blanks 6, 8. Despite thevery different key blank 6, 8 sizes and shapes, the key blank carriers2, 4 each have common features and characteristics to enable use of thetwo key blank carriers 2, 4 in the same key cutter (see example of FIG.4). In this particular implementation, the key blank carriers 2, 4 eachcomprise a key blank recess 10 at least partially within a key bladesleeve 12, 14.

The key blank carrier 2, 4 of FIGS. 2A and 2B each comprises a tip end28 having a width CWt1, CWt2, and a head end 30 having a width CWh1,CWh2, and a total length CL1, CL2. The head end 30 comprises asubstantially planar carrier flag 15 extends from the key blade sleeve12, 14 toward the key blank 6, 8 head. The substantially planar carrierflag 15 comprises a key blank head channel 16, 18 adapted for theparticular key blank 6, 8 intended for use in the key blank carrier 2,4. The key blank head channels 16, 18 of the particular implementationof FIGS. 2A and 2B each have a width W1, W2 and a depth D (FIG. 3C)sized to receive the particular key blank 6, 8. Although tolerances arenot required to be exact, the channels 16, 18 should be sized, incombination with the other features of the respective key blank carriers2, 4 to contact the key blank 6, 8 heads and retain the key blanks 6, 8into their designed carrier sufficient for holding the key blank in adesired position in relation to the key blank carrier 2, 4 for cuttingin an appropriately configured cutting system. Although the key blankhead channels 16, 18 of these particular embodiments illustrate achannel width W defined by two opposing channels 16, 18, each with adepth D, in particular embodiments only one channel 16, 18 may be usedif the key blank 6, 8 is otherwise retained into the carrier 2, 4sufficient for cutting. Openings to the channels 16, 18 of theseembodiments comprise a flared wall 20 to assist in insertion of therespective key blanks 6, 8.

Particular embodiments may comprise a security feature, such as aretaining clip 22 positioned adjacent to the key blank head channel 16,18. The retaining clip 22, when used, is configured to flex rearward(FIG. 3A) of the carrier flag 15 from a rest position (FIG. 3B) alignedwith the carrier flag 15 so that when the key blank 6, 8 is fed into thekey blank recess 10 through the key blank channel 16, 18, the retainingclip 22 flexes rearward to allow the key blank 6, 8 to pass into the keyblank channel 16, 18 and return back to its rest position when the keyblank 6, 8 head has passed. In the rest position, the retaining clip 22secures the key blank 6, 8 into the key blank recess 10 when the keyblank is in a fully inserted position in the recess (FIGS. 2A and 2B).Reference numbers and/or letters 24 may be included on the key blankcarrier 2, 4 to indicate the key blank packaged in the carrier or thekey blank for which the carrier was configured. A dispensing or displayaperture 26 may be included at or near an edge of the carrier flag 15.Use of a reentrant opening aperture 26 such as that illustrated in FIGS.2A and 2B provides particular advantage with a rigid dispensing systemsupport developed herewith but disclosed in more detail in a separateapplication.

The tip end 28 of the key blank carrier 2, 4 comprises at least aportion of the key blank recess 10 embodied as a key blank sleeve 28.The key blank recess 10 comprises at least two walls 32, 34, 36, 38(FIG. 3C) that when a key blank 6, 8 is inserted into the recess 10contacts at least two sides of the key blank 6, 8. For the embodimentsillustrated in FIGS. 2A and 2B, the key blank recess 10 embodied as akey blank sleeve 28 contacts at least two sides of the key blank 6, 8blade. The overall key blank carrier 2, 4 comprises a depth CD. Becausein many cases the carrier is designed to be disposable and/or sold withthe particular key blank which it holds, and because the carrier itselfdoes not require any additional clamps or moving parts, it can be madesmall. In a particular implementation, the carrier width CWh1, CWh2 isnot more than 3 inches at the carrier flag, the carrier width CWt1, CWt2is not more, than 3/4 inch at the sleeve, the carrier depth CD is notmore than 1/2 inch and the carrier length CL1, CL2 is not more than 4inches. Particular embodiments, of course, are adapted to specific keymodels and will be configured relative to their respective sizes. Thus,smaller key blank carriers are likely and contemplated, In a particularembodiment, a key blank carrier has a carrier width CWh1, CWh2 ofapproximately 2 inches at the carrier flag and a carrier width CWt1,CWt2 of approximately 1/2 inch at the sleeve, approximately 3/8 inchcarrier depth CD and approximately a 3 inch carrier length CL1, CL2.

The key blank carrier walls 32, 34, 36, 38 each comprise a thickness of3/8 inch or less, and in particular embodiments, a thickness of ¼ inchor less so that the key blank carrier walls 32, 34, 36, 38 do not extenda significant distance from the key blank in relation to the thicknessof the key blank. The inside of the key blank recess is configured andadapted to closely hold the particular key blank 6, 8 for which thecorresponding carrier 2, 4 is designed. This may be accomplished in manydifferent ways, but one particular way is to include one or more ridges35 in at least a portion of the key blank carrier sleeve 12 to mate witha keyway (groove in the key blade) of the key blank. Although it is notnecessary to match the shape of the particular key blank 6, 8, it isdesirable in particular embodiments to snugly hold the particular keyblank 6, 8 so that the particular key blank 6, 8 does not freely movewithin the recess. The carrier 2, 4 ultimately is inserted into a keycutter adapted to engage the carrier 2, 4 which positions the key blankblade for accurate cutting by the key blank cutter. If the key blank 6,8 is not positionally secured within the carrier 2, 4 when the carrier2, 4 is inserted into the key blank cutter, the key blank may not beaccurately positioned by the key blank carrier 2, 4 or accurately cut bythe key blank cutter. In other particular implementations, the key blankrecess may comprise the key head channel with or without a key bladesleeve. The key blank carrier 2, 4 may be a disposable plastic carrierwhich is used for one or more of displaying the key blank on a displayor in a vending machine, dispensing the key blank from a vendingmachine, verifying that the selected key blank is correctly selected,positioning and holding the key blank in the key blank cutter, andbearing the check-out code 52 (such as a bar code or alphanumeric code)(FIG. 3D) with which the user can pay for the key blank.

In particular implementations of a key vending system, the vendingsystem may dispense a separate key blank carrier that is not mated withthe key blank when dispensing the key blank. The user may be instructedto insert the key blank into the carrier before inserting the carrierand key blank into a key blank cutter. A key blank carrier, whetherdispensed separately or previously incorporated with the key blank, maycomprise a sleeve and/or a head cap or other alignment fixture thatremovably couples to the key blank. In particular implementations,ridges on an inside surface of the key blank carrier may be positionedand configured to engage grooves on the key blade to more securely holdthe key blank within the carrier.

In particular embodiments of a key blank sleeve 10, a portion of thewalls 32, 34, 36, 38 may be removed or recessed to expose all or aportion of the key blade for cutting through an aperture in a carrierwall, which aperture may be configured as a recess on a side of at leastone of the carrier walls as illustrated in FIGS. 2A, 2B. In otherparticular embodiments, however, the key blade may not be exposed andthe key may be cut through the carrier 2, 4. The walls 32, 34, 36 and 38of the embodiment of FIGS. 2A, 2B and 3C comprise a key blade bit sidewall 32 (corresponding to a side of the key blank blade into which thekey bit pattern is cut), key blade spine side wall 34 (corresponding toa side of the key blank blade called the spine), a front side wall 36and a back side wall 38. In the embodiment of FIGS. 2A and 2B, theportion of at least the front and bit sides is missing or recessedbetween the head end 30 and a distal end 40 of the tip end 28 thatexposes a majority of a bit edge 7, 9 of the key blank 6, 8 when the keyblank 6, 8 is in its fully inserted position in the key blank carrier 2,4 (FIGS. 2A and 2B).

Standard carrier features and characteristics may be included on aplurality of carriers designed for a variety of key blank makes andmodels. For example, although the characteristics of the key blankrecess will be different for different key blanks to receive and holdthe key blanks, external characteristics of the carriers may be made thesame so that the carriers all interact with a standard key blank cutteraperture to receive and position the key blank blades of all key blankswithin an appropriately configured carrier in a correct location inrelation to a cutting wheel of the cutter. Variations in key blanksrequire that for an accurate cut, the key blank must be positionedaccurately within a three-dimensional space adjacent to the cuttingwheel. By adapting relative carrier dimensions, all key blanks may beaccurately positioned by a corresponding appropriately configuredcarrier in a key blank cutter. There are many variations possible foreach key blank make and model depending upon the particular key blankcutter and key blank cutter aperture used. The examples provided in thisdisclosure are intended to be representative for purposes ofcommunicating the idea but not limiting as to the limits of the possiblevariations. Those of ordinary skill in the art will readily understandfrom this disclosure the appropriate adjustments to be made forparticular embodiments given the various parameters of a particularsystem and key blank.

In a particular key blank carrier embodiment, the key blank recess maybe positioned more toward the spine side 34 or to the bit side 32, moretoward the front side 36 or toward the back side 38 (in anyimplementation or embodiment, whether configured as a key blank bladesleeve or simply as a key head recess), and may be positioned moretoward the distal end 40 or toward the head end 30 of the carrier(relationally speaking to enable the key blade to be positioned fartheror less into the cutter). On an outer surface of the carrier 2, 4, a keyblank cutter alignment feature may be included. Although the embodimentsof FIGS. 2A, 2B and 3C illustrate ridges 42, 44, other key blank cutteralignment features may be used such as, by non-limiting example, ridges,grooves, shaped cutter cross-sections, clips and the like to mate with acorrespondingly shaped portion of the key blank cutter aperture toproperly align the key blank carrier within the cutter for accuratelycutting the particular key blank for which the key blank carrier wasdesigned.

A particular implementation of an alignment feature may comprise a firstridge 42 on an outer surface of the sleeve 12, 14 extending lengthwisealong a portion of the sleeve 12, 14. In the particular embodiment ofFIGS. 2A, 2B and 3C, the first ridge 42 extends along a border of thekey blade sleeve 12, 14 adjacent the key blank spine side 34. Inclusionof the ridge along the border adjacent the spine side 34 allows forstable support for the ridge 42 while allowing the front side 36 of thesleeve 12, 14 to flex enough for a key blank clamp of a key blankcutting system to clamp the key blank carrier 2, 4 with sufficient forceto flex the carrier 2, 4 outer surface of the sleeve 12, 14 toward thekey blank 6, 8, causing the sleeve 12, 14 to more securely grip the keyblank 6, 8 within the sleeve 12, 14 through the carrier 2, 4 prior tocutting. Other embodiments may include a ridge in other locations on thesleeve 12, 14 or head flag 15.

Inclusion of a ridge 42 on the front side 36 of the sleeve 12, 14creates an asymmetrical shape for an end view of the tip end 28 of thesleeve 12, 14 that inserts into a key blank cutter. The end view of thetip end 28 for particular embodiments may be made unique enough to allowinsertion of the tip end 28 in only one orientation, that unique shapebeing asymmetrical for all but not more than one cross-section of theshape. Having a shape that is asymmetrical for all but not more than onecross-section of the shape ensures that the insertion orientation of thekey blank carrier is always known. For a single-side cut key, the keyblank bit side should be properly oriented in a key blank cutter so thatthe key blank bit side is oriented toward the cutting wheel. If it isimproperly oriented, the key blank spine side will be cut. Fordouble-side cut keys, such as some automobile keys for example, bothsides of the key may be cut with mirrored patterns. In this case, it isnot important to cutting the key blank whether a first or a second keyblade edge is facing the cutting wheel, but only that it is correctlypositioned within the key blank cutter aperture in relation to thecutting wheel and oriented correctly in relation to the wheel with thefirst or second key blade edge facing the wheel. Nevertheless, it may beimportant which edge of the key blank carrier is facing up or down forimplementations involving an identifying bar code sticker (FIG. 3D), topermit the bar code to be scanned. In particular embodiments, such asthat illustrated in FIG. 3C, a second ridge 44 may be included on asecond side, such as the back side 38, of the sleeve 12, 14 to furtherassist in alignment.

In particular embodiments of the implementation illustrated in FIGS. 2Aand 2B, an aperture or slit 48 may be included in a front 36 or back 38side of the sleeve 12, 14. In the particular embodiment illustrated inFIGS. 2A and 2B, the slit 48 is included along a border of the bit side32 of the carrier 2, 4 sleeve 12, 14. Addition of the slit 48immediately adjacent to the bit side 32 of the sleeve 12, 14 providestwo key advantages. First, the slit allows the front side 36 of thesleeve 12, 14 to be less rigid and to flex when a key blank cutter clamppresses against the outer surface of the sleeve 12, 14. This furtherenables secure holding of the key blank in the cutter during cutting ofthe key blank 6, 8. Second, the slit 48 positioned immediately adjacentto the bit side 32 of the sleeve 12 permits the bit side 32 of thesleeve 12 to flex outward slightly away from the bit edge of the keyblank blade when a key blank 6, 8 is inserted into the sleeve 12. Bymaking an internal dimension of the sleeve 12 slightly less or exactlythe same as the key blank 6 for which the sleeve 12 is designed,ignoring tolerance variations, the key blank 6 bit edge can contact thebit side wall 32. Even if manufacturing tolerances are off for theparticular key blank 6 or the carrier 4, the carrier 4 can adjust to thewidth of the key blade and still cause the carrier to press the keyblade against the spine side wall 34 of the sleeve 12.

In some implementations, the distal end 40 of the carrier 2, 4, may bemade a known length from where a shoulder 50 of the key blank 6, 8 willsit in the carrier 2,4 for the particular key blank 6, 8 so that the keyblank cutter can sense that the key blank has been fully inserted intothe cutter and is ready to be clamped for cutting. In some embodiments,such as those illustrated in FIGS. 2A and 2B, the known length may belonger than the key blade for the particular key blank for which thecarrier 2, 4 is designed. By establishing the relative dimensions of thecarrier 2, 4 in relation to the particular key blank for which thecarrier 2, 4 is designed, the relative positioning of the key blankshoulder 50 can be accurately known for accurate positioning in thecutter and accurate key blank cutting of the key bit pattern in relationto the key blank shoulder 50.

In particular embodiments, a leading edge of the ridge 42 may be taperedtoward the outer surface of the sleeve 12, 14 as the ridge 42 nears thedistal end 40 of the key sleeve 12, 14. Tapering toward the outersurface allows the shape of the end view of the sleeve 12, 14 to moreeasily insert into a mating shape on the key cutter. Additionally, inparticular embodiments, a divot 46 (FIGS. 3B and 3C) may be included inone or more ridges 42, 44 on the key sleeve 12, 14. Inclusion of a divot46 allows for a reference point on the key sleeve that can be used by akey blank cutter to engage the key blank carrier 24 (see FIG. 5D andrelated discussion). For the rounded divot illustrated in FIGS. 3B and3C, the divot 46 in the carrier 2, 4 is positioned to engage a springbiased clip in the cutter when a user inserts the carrier 2, 4 into thecutter and gives the user a tactile response to know that the carrier 2,4 is fully inserted. Although the example illustrated in FIGS. 3B and 3Cinclude the divot 46 in one or more ridges 42, 44, a similarlyfunctioning reference point on the carrier 2, 4 may be made at otherplaces on the carrier 2, 4 in other embodiments and implementations. Inother particular implementations, the distal end 40 of the sleeve 12, 14may have one or more tapered outer surfaces to simplify insertion of thesleeve 12, 14 into an aperture on the key blank cutter.

Particular implementations of a carrier, such as that illustrated inFIGS. 2A and 2B, may comprise a reference indicator on the carrier 2, 4indicating to the user which side is up and in which direction the usershould insert the carrier 2, 4 into a key blank cutter. In particularembodiments, the reference indicator 56 may comprise an arrow placed onthe sleeve 12, 14. In more particular embodiments, the referenceindicator 56 may be an aperture through the front side wall 36 of thesleeve. Although other physical attributes of the key blank carrier maybe configured to physically require the key blank to be inserted in aparticular orientation, a visual indicator that is physically part ofthe key blank carrier, not just a sticker adhered to the carrier thatmay fall off, may help the user in using the key cutting system. Whetherused as an indication to the user or not, a reference indicator such asan aperture through a wall of the sleeve 12, 14 or other referenceindicator on the carrier 2, 4 may be included on the carrier 2, 4 thatfunctions as a reference point for the key blank cutter to ensure thekey blank carrier 2, 4 is fully inserted into the key blank cutter. Thismay be confirmed through the portion of the key blank carrier 2, 4 inmany different ways, such as, without limitation, engaging a switchwithin the cutter, blocking a light beam, or allowing a light beam.

Particular implementations of a carrier, such as that illustrated byFIG. 3D, may further comprise one or more bar code stickers 52 and/orother machine readable identifier, such as a radio frequencyidentification (RFID) tag 54 on the carrier, to assist in inventorytracking, security, product verification and checkout. For example,inclusion of a bar code sticker 52 on a back surface of the carrier 2, 4of FIG. 2A or 2B over the retaining clip 22 may be used to restrictflexing of the retaining clip to further restrict key blank removal fromthe carrier 2 without damaging the sticker 52. The bar code on thesticker 52 may also be used by the key blank cutter to confirm that theparticular key blank being cut is an appropriate key blank for themaster key identified by the system. The bar code on the sticker 52 mayalso be used for product checkout at a cash register to allow the userto pay for the duplicate key after it is cut. An RFID tag 54 may be usedfor any of these uses as well, but also has an advantage of beingtrackable from a distance. Particular implementations comprise an RFIDtag on or in the carrier, and in particular embodiments, the RFID tag isincluded on or in the key sleeve.

As will be clear to those of skill in the art, the various featuresillustrated in reference to the various embodiments and implementations,even if not specifically discussed with reference to a particularembodiment or implementation may be included in any embodiment orimplementation depending upon the needs of a particular application ofthe technology. The differing examples provided herein are not intendedto be limiting of particular features to particular examples.

FIG. 4 illustrates an example of a detailed cutting process. In FIG. 4,a bit pattern reading device outputs the master key bit pattern to thekey blank cutter. The reading device may send the bit pattern to thecutting portion through electrical signals, mechanical movements, orother information transfer methods. The identification process mayoutput the key blank type to the user, may simply dispense a correctlyconfigured key blank or may allow the user to select from a variety ofcorrectly configured key blanks to match the identified master key.Particular embodiments of the output may be in the form of a color code,an alphanumeric code, or other identifiable method so the user mayselect the correct key blank from the matching code on the carrier. In aparticular implementation, the key blanks may be stored in a rack ordispensing machine. The user may select the key blank and then insertthe key blank into the machine. Upon insertion of the key blank andcarrier into the key cutter, a reference indicator, such as on a keyblade sleeve tip or key blade head clip indicates that the key blank andcarrier are fully inserted into the cutter.

At any point of the cutting process, the key blank may be verified toensure that the correct key blank was selected. The verification stepmay occur prior, during, or after insertion into the cutter. The stepmay occur automatically or the user may be prompted to complete thisstep. Particular embodiments may include a prompting to the user to scanthe key sleeve in a barcode reader or the system automatically readingthe key bar code or RFID tag code upon insertion by the user. If the keyblank is wrong, the machine may prompt the user to select the correctkey, disable the machining capabilities of the machine, or by anothermethod inhibit the equivocal duplication of a key blank. The cuttingportion of the key may clamp the key and the cutting wheel duplicatesthe bit pattern into the blade of the key blank. If the key is a doublesided key, the machine may automatically flip the key, prompt the userto turn the key over, or by another method cut two sides of the key.

The following is an abbreviated description of an example of a keycutting operation using a key carrier. FIGS. 5A-5E illustrate variouscross-sectional views of an example of a key blank cutter 90 with acutting wheel 92, the key blank cutter 90 adapted for cutting a keyblank 100 in a key blank carrier 102 embodied as a key sleeve. FIGS.5A-5C illustrate a top down cross-sectional view of the cutter 90 withthe key blank 100 in its carrier 102. FIG. 5A illustrates the key blank100 in its carrier upon removal from the cutter 90. The cutting wheel 92may be disengaged and the key entry 94 opened prior to insertion of thecarrier 102. One or more alignment features 104 on the carrier 102 and atip end view shape of the carrier 102 (see FIG. 5E) ensure that the keyblank 100 is properly positioned within the cutter 90 in relation to thecutting wheel 92 including that the key blade bit edge is facing towardthe cutting wheel 92 (FIG. 5B). When the key blank carrier 102 of thisembodiment is fully inserted, a carrier tip sensor 96 senses that thecarrier 102 is fully inserted and the carrier 102 and key blank 100 areclamped in place. After one or more carrier 102 and/or key blank clamps98 (FIG. 5D) are engaged, the cutting wheel 92 contacts the key blade(see FIG. 5C) to duplicate the appropriate bit pattern as determined bythe identification process. FIG. 5D illustrates a side cross-sectionalview of the embodiment of FIG. 5A, illustrating clamps extending along alength of the key blank 100 blade. In the embodiment illustrated, thetip sensor 96 is embodied as a hook shaped cam that interfaces with asensor contained in the cam housing 95 and a divot 106 in the key blankcarrier. The one or more clamps press at least a portion of the keyblank blade, and thereby may immobilize the key blank during cutting.FIG. 5E illustrates a cross-sectional sleeve distal end view of theclamp 98 and key blank blade 105 which is orthogonal to the view of FIG.5D. In this view, the one or more alignment features 104 on the carrier102 are shown to interface with corresponding features 106 on thecarrier aperture and in this embodiment even with the one or more clamps98 themselves. Interface between the one or more alignment features 104and corresponding features on the one or more clamps 98 themselvesfurther provides stability for the key blank 100 and its carrier 102during cutting. The one or more clamps 98 may or may not directlycontact the key blank blade 105 during the cutting process and may clampthe key blank 100 through the carrier 102 or through a combination ofdirect contact with the key blank 100 and through the carrier 102.

In particular implementations, after any portion of the cutting process,secondary processes may be employed to further prepare the key for use,such as removing extra features from the key such as extended tips,knobs, or ridges. The key may also be deburred by passing the cuttingwheel across the key bits a second time to clean them up and smooth themout. At any point after cutting the key bit pattern into the key blank100, the key duplication system may have a verification method fordetermining if the now duplicated key matches the master key. Theverification may occur within the cutting area of the cutter, or in aseparate location.

FIG. 6 illustrates another embodiment of a carrier 110 comprising manyof the similar features to the particular embodiments described withreference to FIGS. 2 and 3 and description of those Figures should applyto the particular embodiment of FIG. 6 with the exception of the twoelements discussed here. In the particular embodiment of FIG. 6, thoughthe feature may be included in any other embodiments as well, anaperture 112 is included through the substantially planar key headsurface that is sized and shaped to mate with the cross-sectionalprofile of the master key matching the key blank for which the carrieris designed. Inclusion of a mating aperture similar to a lock keywayopening, allows the user to further confirm that the key blank the useris about to cut for the master key matches the master key. A displayaperture 114 is also included, similar to the display aperture 26 ofFIGS. 2A and 2B, but in this case the display aperture 114 is not areentrant opening aperture. Instead, it is simply an aperture thatpermits a display rod to be inserted there through for displaying theproduct prior to sale. Either aperture type may be used on any of theembodiments disclosed herein depending upon the needs of a particularproduct display or vending unit.

FIGS. 7A and 7B illustrate, respectively, another embodiment of a keyblank recess implemented as a key blank blade sleeve. FIG. 7A shows aperspective view of a front side of each of two key blanks 116, 118 fromdifferent manufacturers within key blank carriers 120, 122 designed forthose specific key blanks, and FIG. 7B shows a perspective view of aback side of the key blanks 116, 118 within the key blank carriers 120,122. Many of the same features discussed in relation to the carriers andkey blanks discussed in relation to FIGS. 2 and 3 are shown in theembodiments of FIGS. 7A and 7B, such as but not limited to, alignmentfeatures 130 on the key blank carriers 120, 122, key blank recessesembodied as sleeves, apertures through the sleeves, substantially planarportion extending toward the key head, bar code sticker on the back sideof the substantially planar portion, and the like. Additionally,however, there are features not previously illustrated in otherembodiments that are illustrated here. Other embodiments discussed inthis disclosure may include any of these additional features in additionto or instead of some of the features included on those otherembodiments. In particular embodiments, a security feature 124, in FIGS.7A and 7B embodied as a retaining clip 124, may be included on thecarrier to physically engage with a corresponding feature on the keyblank 116, 118. The retaining clip 124 allows the key blank to beinserted into the carrier sleeve, but once the clip engages with anadditional notch 126, cut out from a side of the key blank 116, 118, thekey blank is locked into the carrier to restrict its withdrawal untilthe retaining clip 124 is cut, broken, bent or released to release thekey. Key blanks typically do not have notches cut out from above theshoulder of the key blank. However, a notch between the shoulder of thekey blank and the key blank head may be used to engage the key blankwithin the key blank carrier. In particular cutting methods, thesecurity clip may be cut by the cutting wheel prior to the cutterreleasing the key blank carrier to release the cut key blank from thekey blank carrier. In other particular methods, the user bends or breaksoff the clip to remove the key from the carrier. The additional securityfeature may additionally or alternatively include retaining clips thatinterface with any portion of the key blank blade, rivets, rings,plastic loops, ties, tabs, glue, other adhesives, and other securingmethods. These devices may be removed by a variety of methods includingmechanically releasing the key, cutting, breaking, or bending thesecurity feature, dissolving, or any other process appropriate to removethe security feature. The security features may be incorporated byprimary manufacturing processes for they key blank such as, but notlimited to, casting, pressing, or punching, or by secondarymanufacturing processes such as milling, cutting, press fitting, plasticpress molding, and so on.

FIGS. 8A and 8B illustrate front and back perspective views of anotherembodiment of a key blank carrier 127 comprising a large carrier flag128, a retaining clip 124, and alignment features 130 with divots 132. Aportion of the key blank sleeve is recessed to reveal a portion of thekey blank blade 134 for cutting.

FIGS. 9A and 9B illustrate front and back perspective views of a keyblank carrier for a double-sided key 136. This embodiment is configuredsimilar to the embodiment of FIGS. 2 and 3, but the carrier 138 includesopenings along both edges of the key blank blade to correspond to theedges of the key blank blade that need to be cut in the cutter. Thecarrier 138 includes a tapered distal end 140 and appropriatelyconfigured and positioned alignment features 130. FIG. 9C illustrates adistal tip end view of the key blank carrier of the embodiment of FIGS.9A and 9B. Note that an end view of the walls of the sleeve incombination with the key blank alignment features 130 form a shape 141that is asymmetrical about all cross-sectional axes X (see FIG. 9D).FIGS. 10A and 10B are distal tip end views of two additional key blankcarriers illustrating different distal tip end view shapes. The exampleof FIG. 10A is asymmetrical for all cross-sections, but the example ofFIG. 10B is asymmetrical for all but one cross-section (down themiddle). By using an end view with a carrier insertion shape (the partthat inserts into a cutter) that is asymmetrical about all but onecross-section of the shape, the user can be assured to insert thecarrier in a known orientation for cutting the key blank. For singlesided keys (FIG. 10A), this is important because a single sided keyinserted backward will be cut with the bits on the spine of the keyblank resulting in a non-functional duplicate key. For double sided keys(see FIG. 9C), the alignment features 130 may be positioned equidistantfrom a center axis on opposing front and back sides of the carrier 138so that the carrier 138 can be removed and rotated 180 degrees if only asingle cutting wheel is used in the cutter and manual rotation isrequired for a particular implementation of a cutter.

A non-limiting example of a standard alignment feature for multiplesingle and double sided carriers to interface with a single cutter keyblank aperture may comprise an aperture that has three grooves; two onthe top and one on the bottom of the aperture opening. A single sidedkey sleeve may have three corresponding ridges, whereas a double sidedkey sleeve may have two ridges (one on top and one on bottom) such thatthe key sleeve may be flipped and inserted into the same aperture.Another example may be a hole with two grooves on one side that mateswith a carrier that has one or two ridges on the corresponding side,thus allowing the sleeve to be inserted in only one orientation. Otherconfigurations may employ any combination of alignment features, some ofwhich may allow for a distinction between key blank sleeve types.

FIGS. 11A and 11B illustrate front and back plan views of a key blankcarrier embodiment with a differently shaped flag 142 and a tapereddistal end 140 of the key blank carrier. Each implementation of a keyblank carrier disclosed herein may comprise only one or all of thevarious features discussed in relation to the other implementations andembodiments of key blank carriers, and the examples provided hereininvolving combinations of features is not intended to be limiting ofwhich features may be used together in a particular embodiment.

FIG. 12 illustrates a particular implementation of a key blank carrier150 comprising a hinge 152 along a first side that allows a front side154 of the key blank carrier 150 to be hinged open for insertion of akey blank 156 into the key blank recess of the carrier 150. The hingemay be configured as a living hinge formed in a single molding processwith the remainder of the carrier, or may be formed with a first portionof the hinge on a carrier base 158 and a second portion of the hinge onthe front side 154 of the carrier 150, wherein the front side hingeportion and the base side hinge portion mate to form the hinge. Thehinge may hinge near the tip of the key, the head of the key, along aside of the key as illustrated in FIG. 12, or near any other location. Aclosing latch 159 may also be included at any number of possiblelocations to assist in holding the front side 154 closed against thecarrier base 158. Particular implementations may not include a closinglatch 159 at all, and other particular implementations, such asillustrated in FIG. 13, may not include a top side of the key blankcarrier at all.

For any of the implementations discussed in the present disclosure, butparticularly for the implementations illustrated through the embodimentsof FIGS. 12, 13 and 14, the key blank carrier may be configured as inFIG. 12 wherein a key blank carrier 160 comprises raised side wails 162that restrict side movement of the key blank 156 within the carrier 160around portions of the key blank blade 164 or the key blank head 166 orboth. As with earlier implementations exposing the key blank blade forcutting, any implementation, but particularly for the implementationsillustrated through the embodiments of FIGS. 12, 13 and 14, portions ofraised side walls 162 may be removed near the key blade blank 164 toprovide easier access by the cutting wheel of the key blank blade 164for cutting, to remove the need to cut through the key blank carrier 160to cut the key blank blade 164, and to avoid leaving the key bit patternof the master key in the cut key carrier 160.

FIG. 14 is a perspective view of a key blank carrier 170 comprising ahandle 172 extending from the spine side 174 of the key blank carrier170. Use of a handle 172 extending from the spine side 174 of the keyblank carrier 170 or elsewhere on the key blank carrier 170 allows foruse of the key blank carrier 170 in a side-mount configuration where thekey blank 156 is inserted into a key blank cutter sideways with the bitedge 175 of the key blank 156 facing the cutting wheel. Alignmentfeatures 176, embodied as ridges similar to previous implementations andembodiments or as any other embodiment discussed herein, may be includedon the key blank carrier as with other embodiments, just orienteddifferently so that the unique shape for mating with an opening in thecutter is viewed in relation to a side of the carrier for key blank sideinsertion rather than for key blade tip insertion.

FIG. 15A illustrates a key blank 180 with an oversized key blank head182 having a head depth HD greater than its blade 184 depth BD. FIGS.15B-15G are front, right side, back, head end, tip end and close-upviews of a key blank carrier 186 holding the key blank 180 of FIG. 15A.In this particular embodiment a locking notch 188 is cut into the keyblank 180 between the key blank head 182 and the distal end 190 of thekey blank blade 184. Non-limiting examples of a key blank 180 with anoversized key blank head 182 include a key blank 180 having atransponder within the key blank head 182, and a key blank 180 with arubberized or plastic key blank head 182 or coating over a key blankhead 182. Many automobiles and other security keys include transponderswithin the key head 182, resulting in a larger key head depth HD andoverall size. In the embodiment illustrated in FIGS. 15A-15G, to adaptfor a key blank head 182 with a depth HD greater than its blade 184depth BD, a step 192 is added between the substantially planar key blankcarrier flag 194 and a key blank sleeve 196. It will be understood bythose of ordinary skill in the art and is specifically contemplated bythis disclosure, that the additional feature of the step 192 between thekey blank carrier flag 194 where the key blank carrier flag 194 isrecessed back from the and the key blank sleeve 196 may be applied toany of the specific key blank carrier implementations and embodiments ofFIGS. 2, 3, 6, 7, 8, 9, 10, 11, 12, 13 and 14, and the features of thoseother specific embodiments may be equally applied to the embodiment ofFIG. 15. The respective descriptions of each of those embodiments andimplementations should be treated as though they each include expressadditional embodiments illustrating the combination of this step featureand alternative or additional security feature into those descriptions.

The specific embodiment illustrated in FIGS. 15B-15G includes many otherkey blank carrier 186 features discussed previously in relation to otherkey blank carriers. Examples of some of these features include key blankalignment features 198, a tapered key blank carrier distal tip end 200,a substantially planar key blank carrier flag 194 at a head end,portions of the key blank 180 exposed through the carrier along the keyblank blade 184, a bar code 202, an RFID tag 204, and a key blankretaining clip 206. In this particular embodiment of a key blankretaining clip 206, a release tab 208 extends from the flexibleretaining clip 206 and back-and-forth movement of the release tab 208causes corresponding movement of the retaining clip 206 into and out ofthe locking notch 188 on the key blank 186. In the particular embodimentof FIGS. 15B-15G, the release tab 208 extends along, adjacent andparallel to an edge of the key blank carrier flag 194, perpendicular tothe retaining clip 206 that mechanically engages the key blank blade184.

FIGS. 16A-16C illustrate, respectively, front, right side andperspective views of a key blank 210 in a key blank carrier 212comprising a key blank recess 214 configured to receive a key blank head216. Similar to key blank carrier embodiments previously discussed, thekey blank carrier 212 of this embodiment comprises key blank carrieralignment features 218 adapted to interface with a front side of a keyblank cutter. In the embodiment illustrated in FIGS. 16A-16C, a securityfeature is configured as a retaining clip 220 that flexes forward of thesubstantially planar key blank carrier flag 222 when a key blank head216 is inserted into the key blank recess 214 and the retaining clip 220inserts into and engages the key ring hole 221 of the key blank head216. Similar to embodiments discussed herein comprising key blankrecesses embodied at least in part as key blank blade sleeves, the keyblank blade recess 214 of the embodiment illustrated in FIGS. 16A-16C issized and configured to securely hold the key blank 210 in a knownposition in relation to the key blank carrier 212 so that when the keyblank carrier 212 is mechanically engaged with a mechanically matingfeature on a key blank cutter, the key blank blade 224 is accuratelypositioned for cutting the specific key blank blade 224 for which thekey blank carrier 212 is designed. Also as with previous embodimentsdiscussed involving a key blank blade sleeve, key blank carrier 212implementations and embodiments may be adapted for different key blankmodels by resizing and shaping the key blank recess 214 to fit the sizeand shape characteristics of the different key blank models in a waythat holds them securely when at least the key blank head 216 isinserted into the key blank recess 214 of the key blank carrier 212.

FIGS. 17A-17C illustrate, respectively, front, right side andperspective views of a key blank in a key blank carrier 226 comprisingkey blank recess 228 configured to receive a key blank head 216 and anextended key blank alignment feature 230 extending along a portion ofthe key blank blade 224, parallel to an insertion direction of the keyblank blade 224 into a key blank cutter. For this particularimplementation, the key blank alignment feature 230 is an extension ofthe key blank carrier 226 substantially planar portion 232 that directlycontacts the key blank head 216. The key blank alignment feature 230extends along the key blade 224 and includes a ridge 234 similar to thatincluded in previous embodiments and an optional divot 236 on the ridge234 similar to previous embodiments. In some implementations, the keyblank carrier 226 portion adjacent the key blank head 216 may be madevery small such that includes roughly a key blank carrier flag with aretaining clip and key blank channel. An alignment feature like that ofFIGS. 17A-17C could then be used and materials (namely plastic) usagecould be kept to a minimum. Alignment features 230 are not required onthe key blank carrier 226 near the key blank head 216.

Other features such as the reentrant opening on the key blank carrierflag, a mating key blank cross-section aperture on the flag, a divot ona portion of the alignment feature to give the user a tactile responseindication that the key blank carrier is fully inserted and taperededges to the leading edges of the alignment features may be included onthe key blank carrier as discussed in relation to previous embodimentsin addition to the features discussed in relation to the embodiments ofFIGS. 16 and 17.

FIGS. 18A-18C illustrate, respectively, front, right side andperspective views of a key blank 240 adapted to include at least onealignment feature 242 on the key head 244 to assist in aligning the keyblank 240 in a key blank cutter. By presenting any of ridges, knobs,ramps and the like as alignment features 242 on the key blank head 244,the key blank 240 itself may be configured to self-align in the keyblank cutter when the key blank 240 is pushed into the cutter by a user.The combination of alignment features 242, 243, 245 similar to theprinciple applied with the alignment features on the key blank carrier,can not only ensure that the key blank 240 is inserted with the correctside of the key blade 246 facing the cutting wheel if needed, the depthsFD of the alignment features and their left-to-right placement on thekey blank 240 can ensure that the key blade 246, when fully inserted bya user, is properly positioned on both the X and Y axes for accuratecutting. The cutter may also be adapted with additional hardware toensure that the key blank 240 is hilly seated with the cutter interfaceby drawing the key blank into the cutter until it reaches a fullyinserted position. For the embodiment of FIG. 18A, both horizontal andvertical alignment features 242, 243, 245 are included, the verticalalignment features 242 ensuring straight insertion and the horizontalalignment features 243 providing a stop for indicating full insertion into the cutter. In the particular embodiment illustrated in FIG. 18B, aramped alignment feature 245 is included on a back side of the key blank240. The alignment features 242, 243, 245 on a key head 244, thoughunusual for typical key blanks, can also be designed to be decorativeand ornamental in additional to having the functional purpose ofensuring proper alignment of the key blank 240 with the cutter so thatthe unusual alignment features are more readily accepted. In particularimplementations, the alignment features may be incorporated into adesign for an oversized key blank head such as that illustrated in FIG.15.

FIGS. 19A-19C illustrate, respectively, front, right side andperspective views of a key blank 250 adapted to include an alignmentfeature 252 on the key blade tip 256 in addition to key head 258alignment features 253, 254, 255 similar to the key head alignmentfeatures 242, 243, 245 of the embodiment shown in FIGS. 18A-18C. Once akey blank is correctly inserted into a key blank cutter and clamped inplace, the alignment features are less important than during initialinsertion, and in many cases are useless. Although the embodiment of thekey blank illustrated in FIG. 19 would not work in a typical lock inthis form, it is contemplated that as part of the key blank 250 cuttingprocess that the key blank cutter would cut off the portion of the keyblank distal end tip 256 that includes the alignment ridge 252.Inclusion of one or more additional alignment features 252 near a keyblade tip 256 of a key blank 250 may reduce the number of alignmentfeatures 253, 254, 255 used on the key head 258 for particularimplementations.

For the implementations of FIGS. 18 and 19 where an alignment feature isincluded on a key blank head, it should be understood that the head ofthe key blank, in being made ornamental with the alignment features oreven in other embodiments comprising key blank carriers where it isdesirable to allow for decorative key blanks, the key blanks may becustomized with logos, graphics, or other markings, through processessuch as laser engraving, printing, stamping, engraving, and othermarking processes. In a particular implementation, the key head may bedecorated with dome or other shape attached to the head of the key. Theshape may include team logos, vanity inscriptions, or other personalizedcustomizations. The customizations may include inlaid pictures,engraving, laser engraving, printing, other methods known, or anycombination of these methods. In particular implementations, the keyhead may be customized before or after being cut.

FIG. 20 illustrates a particular implementation of a key blank carrier260. In this particular implementation, the key blank carrier 260comprises a key blank burr removal opening 262 on a side of asubstantially planar surface 264. Key blank burr removal opening 262 maybe V-shaped and may comprise a sharp, beveled edge. The key blank burrremoval opening 262 is useful for removing burrs from a key after a keyblank 266 is cut. After the key blank 266 and key blank carrier 260 areinserted into an opening in a key blank cutter and the key blank 266 iscut by a key blank cutting wheel, the cut key blank 266 and the keyblank carrier 260 are removed from the key blank cutter. The cut keyblank 266 is separated from the key blank carrier 260 and then a blade272 of the cut key blank 266 is moved along the key blank burr removalopening 262 until at least one burr is removed from the cut key blank266. Although in this particular implementation the key blank burrremoval opening 262 is located on a side of the substantially planarsurface 264 near the head of the key, in other implementations the keyblank burr removal opening 262 may be located anywhere on the key blankcarrier 260, on the key blank cutter or on a separate device. In aparticular implementation, the key blank burr removal opening is locatedon a portion of the sleeve of the key blank carrier 260 near the keyblade.

In this particular implementation the key blank sleeve 268 has threeapertures 270 in the front side wall 36 adjacent the spine side wall 34.Although there are three apertures 270 illustrated in this particularimplementation, in other implementations there may be one or moreapertures 270. The apertures 270 may be useful in implementations of akey cutter that includes optics for identifying whether the key blankblade 272 is aligned properly with the spine side wall 34 by viewing thekey blank blade 272 through the apertures 270. Furthermore, theapertures 270 allow the front side wall 36 to be more flexible whenpressed by a clamp to clamp the key blank 266 more securely for cutting.

In the particular implementation shown in FIG. 20, the key blank sleeve268 comprises a shoulder band 274 to more securely hold the key blank266 in proper alignment with the key blank carrier 260. The shoulderband 274, and other features and aspects illustrated in FIGS. 20-23B arenot limited to use only with these particular implementations and may beapplied by those of ordinary skill in the art to any of the otherimplementations illustrated or described in association with thisdisclosure. By specific example, FIGS. 2B, 8A, 8B, 9A, 9B and 15B-15Gall illustrate a shoulder band. The shoulder band 274 in theimplementation illustrated in FIG. 20 surrounds a portion of the keyblank blade 272 and is located adjacent to the shoulder 276 of the keyblank 266. An extended tab 278 is adjacent to the shoulder band 274 onthe front side wall 36 of the key sleeve 268 to prevent the key blankcarrier 260 from being caught on the key blank cutter as it is removedfrom the key blank cutter. In the particular implementation illustrated,the flexible retaining clip 280 is contoured and flares out to assist insmooth insertion of the key blank 266 into the key blank carrier 260.

FIG. 21 illustrates a tip end view of the particular implementationillustrated in FIG. 20. In this particular implementation, a key blankcutter alignment feature 282 extends from the surface of the back sidewall 38 with a first side 284 extending at an angle of about 45 degreesrelative to the surface of the back side wall 38 and a second side 286extending at an angle of about 90 degrees relative to the surface of theback side wall 38. In other implementations, only a first side 284 isnecessary and it is contemplated that the first side 284 may extend atan angle of at least 20 degrees relative to the surface of the back sidewall 38. The location of the key blank cutter alignment feature 282 neednot be located on the back side wall 38 and may be located anywhere onthe key blank carrier 260. In a particular implementation, the key blankcutter alignment feature 282 is integrally formed with the key blankcarrier 260. In a particular implementation, the key blank cutteralignment feature 282 extends lengthwise along at least a portion ofback side wall 38 of the key blank sleeve 268, for example, asillustrated in FIG. 22. One advantage of using a key blank cutteralignment feature is to accurately align a key blank carrier into thekey blank cutter to assist in creating a more accurate and precisecutting of the key blank. As a portion of a key blank cutter pressesagainst the first side 284 of the key blank cutter alignment feature 282of FIG. 20, the key blank carrier 260 tends to move in a directiontoward the spine side wall 34 to assist in aligning the key blankcarrier 260 within the key blank cutter. The angled wall on the firstside 284 of the key blank carrier alignment feature 282 reduces theprecision required within manufacturing tolerances between the key blankcutter and key blank carriers.

FIG. 23 illustrates a particular implementation of a system 288 ofindividual key blank carriers for aligning key blanks 300, 302 within akey blank cutter. The system 288 provides a uniform sleeve thickness STfor all key sleeves 306, 308 in the system 288. The uniform sleevethickness ST allows for a more precise and consistent fit in the keyblank cutter regardless of the type of key blank. Unifying the sleevethickness ST between various key blank carriers for different key blanksreduces the tendency of the key blank carriers and key blanks to rotatewhile the key blank is being cut in the key blank cutter underrotational pressure from the key blank cutter. In this system, thethickness of portions of the front and/or back walls 36, 38 of the keysleeve may vary to account for different sizes and dimensions of keyblades and yet maintain a uniform sleeve thickness 290. Although theparticular implementation of the system 288 illustrated in FIG. 23 onlyshows two embodiments, those of ordinary skill in the art will readilybe able to modify the embodiments from the teachings herein to adapt toany other key size or shape.

Although particular examples of key blank carriers embodied as key blankblade sleeves illustrate and discuss alignment features embodied asridges parallel to the key blank blade, other alignment features arecontemplated and possible for the various embodiments. For example, andwithout limitation, alignment features may be embodied as knobs, ramps,grooves, apertures, shaped key blank carrier portions and the like.Although particular sizes, shapes, lengths, widths and positioning ofparticular key blank and key blank carrier alignment features areillustrated, it will be understood by those of ordinary skill in the artthat such examples are non-limiting and that alignment features in manyother locations and having many other configurations, sizes, shapes,lengths, widths and positioning will function equivalently to thosedescribed herein. Such alternatives should also be considered asequivalent to those described and to the extent they would be understoodfrom this disclosure as meeting the functional capacity as discussedherein, should be considered incorporated within this disclosure.

The components used for a key blank carrier, such as those shown herein,may be made of conventional materials used to make goods similar tothese in the art, such as, by non-limiting example, polycarbonate,polyvinylchloride (PVC) or other rigid or flexible rubbers, plastics, orresins, aluminum, steel, other metals, carbon fiber, Kevlar, othercomposite materials. Those of ordinary skill in the art will readily beable to select appropriate materials and manufacture these products fromthe disclosures provided herein.

The implementations listed here, and many others, will become readilyapparent from this disclosure, From this, those of ordinary skill in theart will readily understand the versatility with which this disclosuremay be applied.

The components included in particular implementations of key blanks andcarriers may be formed of any of many different types of materials orcombinations that can readily be formed into shaped objects and that areconsistent with the intended operation of a key blank or carrier. Forexample, the components may be formed of: rubbers (synthetic and/ornatural) and/or other like materials; polymers and/or other likematerials; plastics, and/or other like materials; composites and/orother like materials; metals and/or other like materials; alloys and/orother like materials; and/or any combination of the foregoing.

Furthermore, the various components forming a particular implementationof a key blank or carrier may be manufactured separately and thenassembled together, or any or all of the components may be manufacturedsimultaneously and integrally joined with one another. Manufacture ofthese components separately or simultaneously may involve extrusion,pultrusion, vacuum forming, injection molding, blow molding, resintransfer molding, casting, forging, cold rolling, milling, drilling,reaming, turning, grinding, stamping, cutting, bending, welding,soldering, hardening, riveting, punching, plating, and/or the like. Ifany of the components are manufactured separately, they may then becoupled or removably coupled with one another in any manner, such aswith adhesive, a weld, a fastener, any combination thereof, and/or thelike for example, depending on, among other considerations, theparticular material(s) forming the components.

It will be understood that implementations are not limited to thespecific components disclosed herein, as virtually any componentsconsistent with the intended operation of a method and/or systemimplementation for a key blank or carrier may be utilized. Accordingly,for example, although particular key blanks, carriers and othercomponents may be disclosed, such components may comprise any shape,size, style, type, model, version, class, grade, measurement,concentration, material, weight, quantity, and/or the like consistentwith the intended operation of a method and/or system implementation fora key blank or carrier may be used.

In places where the description above refers to particularimplementations of key blank or carrier, it should be readily apparentthat a number of modifications may be made without departing from thespirit thereof and that these implementations may be applied to otherkey blanks and carriers. The accompanying claims are intended to coversuch modifications as would fall within the true spirit and scope of thedisclosure set forth in this document. The presently disclosedimplementations are, therefore, to be considered in all respects asillustrative and not restrictive, the scope of the disclosure beingindicated by the appended claims rather than the foregoing description.All changes that come within the meaning of and range of equivalency ofthe claims are intended to be embraced therein.

The invention claimed is:
 1. A method of cutting a key blank to form aduplicate key, the method comprising: inserting a key blank positionedin a key blank carrier into an opening in a key blank cutter; cutting akey bit pattern of a master key into the key blank with the key blankcutter; removing the cut key blank and key blank carrier from the keyblank cutter; separating the cut key blank from the key blank carrier;and moving a blade of the cut key blank along a key blank burr removalopening along a first edge of the key blank carrier until at least oneburr is removed from the blade of the cut key blank.
 2. The method ofclaim 1, wherein the key blank burr removal opening comprises a bevelededge extending for at least a portion of the opening.
 3. The method ofclaim 1, further comprising: mechanically engaging a portion of the keyblank cutter with at least one key blank cutter alignment featureprojecting from a surface of the key blank carrier; and aligning the keyblank with the key blank cutter.
 4. The method of claim 3, wherein theat least one key blank cutter alignment feature comprises a first sideprojecting from the surface of the key blank carrier at an angle of atleast 20 degrees relative to the surface and converging toward a secondside projecting from the surface of the key blank carrier at an angle ofabout 90 degrees.
 5. The method of claim 3, wherein the key blank cutteralignment feature is integrally formed with the body of the key blankcarrier.
 6. The method of claim 1, wherein the key blank burr removalopening is V-shaped.
 7. The method of claim 1, wherein the body of thekey blank carrier comprises an elongated sleeve defining at least aportion of a key blank recess, wherein the key blank recess comprises atleast two walls and is sized and shaped to securely receive at least aportion of the key blank within the recess, wherein the sleeve furthercomprises a tip end and a head end, the head end comprising asubstantially planar surface, and the tip end being at least partlyformed by the at least two walls of the key blank recess and at leasttwo additional walls, and wherein the tip end at least two walls and atleast two additional walls define key blank carrier front and back sidesand key blank carrier bit and spine sides respectively, the key blankcarrier front side comprising at least one aperture extending throughthe key blank carrier front side along an edge of the front sidebordering the key blank carrier spine side.
 8. The method of claim 7,wherein the at least one aperture extending through the key blankcarrier front side comprises at least two apertures extending throughthe key blank carrier front side along the edge of the front sidebordering the key blank carrier spine side.
 9. The method of claim 1,wherein the body of the key blank carrier comprises an elongated sleevedefining at least a portion of a key blank recess, wherein the key blankrecess comprises at least two walls and is sized and shaped to securelyreceive at least a portion of the key blank within the recess, whereinthe sleeve further comprises a tip end and a head end, the head endcomprising a substantially planar surface, the tip end being at leastpartly formed by the at least two walls and at least two additionalwalls, and wherein the tip end at least two walls and at least twoadditional walls define key blank carrier front and back sides and keyblank carrier bit and spine sides respectively, the key blank carrierfront side comprising at least one aperture extending through the keyblank carrier front side along an edge of the front side on the keyblank carrier bit side.
 10. The method of claim 1, wherein the body ofthe key blank carrier comprises an elongated sleeve defining at least aportion of a key blank recess, wherein the key blank recess comprises atleast two walls and is sized and shaped to securely receive at least aportion of the key blank within the recess, wherein the sleeve furthercomprises a tip end and a head end, the head end comprising asubstantially planar surface, the tip end being at least partly formedby the at least two walls and at least two additional walls, wherein thetip end at least two walls and at least two additional walls define keyblank carrier front and back sides and key blank carrier bit and spinesides respectively, the key blank carrier front side comprising at leastone aperture extending through the key blank carrier front side along anedge of the front side on the key blank carrier bit side, the key blankcarrier bit side further comprising a shoulder band adjacent to the headend between the head end and the at least one aperture, the shoulderband extending from the front side of the key blank carrier to the backside of the key blank carrier.